Polyacetal resin composition and molded article thereof

ABSTRACT

An object of the invention is to provide a resin composition, from which a molded article having high durability, sliding property and wear resistance can be produced with a high productivity. 
     The present invention provides a polyacetal resin composition containing 100 parts by mass of a polyacetal resin (A) and 10 parts by mass or more and 100 parts by mass or less of a glass filler (B), in which when a molded article formed of the polyacetal resin composition by molding is fractured by application of tensile force, the surface of the glass filler (B) protruding from a fractured surface of a fractured molded article is covered with a component containing the polyacetal resin (A) having an average thickness of 0.2 μm or more and 3.0 μm or less.

TECHNICAL FIELD

The present invention relates to a polyacetal resin composition and amolded article thereof.

BACKGROUND ART

A polyacetal resin has excellently balanced properties includingmechanical strength such as bending elastic modulus and tensile fracturestress, chemical resistance, sliding property and wear resistance, andis easily processed. Because of this, the polyacetal resin is used as atypical engineering plastic widely used in parts such as machinery partsof electrical equipment and automotive parts.

In particular, for automobile parts requiring durability, a polyacetalresin composition reinforced with an inorganic filler is used. The“durability” means long fracture lifetime, for example, under apredetermined stress, and, in other words, creep resistance.

In the polyacetal resin composition reinforced with an inorganic fillerin order to improve durability, the polyacetal resin is polymerized andthe terminal group of the polyacetal resin is controlled.

Patent Literature 1 discloses a polyacetal resin composition containinga polyacetal resin and a fibrous inorganic filler for improving creepresistance. Patent Literature 1 also discloses that as the molecularweight of a polyacetal resin increases, creep resistance is improved.

Patent Literature 2 discloses a method involving using a plurality ofpolyacetal resins having different contents of a terminal hydroxyl groupin combination in a polyacetal resin composition containing a glassinorganicfiller and a polyacetal resin, to improve interface adhesionbetween the glass inorganicfiller and the polyacetal resin.

Patent Literature 3 discloses that adhesion to e.g., a glass fiber isimproved by using ABA type block copolymer containing a polyacetalskeleton.

Also, as the industrial field of a polyacetal resin is enlarged, it hasbeen desired to improve wear resistance. In an attempt to improve wearresistance, it has been investigated to add an ultrahigh molecularweight polyethylene to a resin composition.

Patent Literature 4 discloses that a lubricant is added in order toimprove the wear resistance of a polyacetal resin composition containinga glass fiber. Patent Literature 4 also discloses that an ultrahighmolecular weight polyethylene is preferable as a lubricant.

Patent Literature 5 discloses that a tribology modifier is added to apolyacetal resin composition containing a glass fiber in order toimprove mechanical strength, wear resistance and sliding property. Inparticular, the literature discloses that an ultrahigh molecular weightpolyethylene having an average molecular weight beyond 1.0×10⁶ g/mole ispreferable as a tribology modifier.

CITATION LIST Patent Literatures

Patent Literature 1: Japanese Patent Laid-Open No. 11-181231

Patent Literature 2: Japanese Patent Laid-Open No. 2004-359791

Patent Literature 3: International Publication No. WO 2001/009213

Patent Literature 4: Japanese Patent Laid-Open No. 9-272802

Patent Literature 5: National Publication of International PatentApplication No. 2014-534301

SUMMARY OF INVENTION Technical Problem

Recently, in machinery parts and automotive parts using a polyacetalresin, further improvement in performance and quality thereof has beendesired.

Improvement in performance, more specifically, refers to improvement ofmechanical strength, durability and wear resistance. The improvement inquality, more specifically, refers to suppression of poor appearance.

However, if a polyacetal resin is polymerized to improve durability,fluidity decreases and molding becomes difficult, causing qualitydeterioration such as poor appearance.

If the number of terminal hydroxyl groups of a polyacetal resinincreases, thermal stability decreases, causing quality deteriorationsuch as poor appearance (silver streaks) during molding.

If an ultrahigh molecular weight polyethylene is added to improve wearresistance, chips are likely to generate due to dropout of e.g., theultrahigh molecular weight polyethylene. When the amount of chipsincreases, malefaction of feeding to a molding machine frequentlyoccurs, extending the duration of a molding cycle. As a result,productivity may decrease.

From the conventional polyacetal resin compositions disclosed in PatentLiteratures 1 to 5, it was impossible to produce a molded article havingexcellent durability, high wear resistance and mechanical strength aswell as excellent in appearance.

The problem to be solved by the present invention is to provide a resincomposition from which a molded article having high durability, slidingproperty and wear resistance can be produced with a high productivity.

Solution to Problem

The present inventors have conducted intensive studies with a view tosolving the above problem. As a result, they surprisingly found that theabove problem can be solved by a polyacetal resin composition containinga predetermined amount of glass filler, from which a molded articlehaving specific characteristics can be obtained and accomplished thepresent invention.

More specifically, the present invention is as follows.

[1]

A polyacetal resin composition containing 100 parts by mass of apolyacetal resin (A) and 10 parts by mass or more and 100 parts by massor less of a glass filler (B) wherein,

when a molded article formed of the polyacetal resin composition bymolding is fractured by application of tensile force, the surface of theglass filler (B) protruding from a fractured surface of a fracturedmolded article is covered with a component containing the polyacetalresin (A) having an average thickness of 0.2 μm or more and 3.0 μm orless.

[2]

A polyacetal resin composition containing 100 parts by mass of apolyacetal resin (A) and 10 parts by mass or more and 100 parts by massor less of a glass filler (B) wherein,

a tensile fracture stress of a molded article obtained by molding thepolyacetal resin composition and measured in accordance with ISO527-1 is135 MPa or more;

a bending elastic modulus of the molded article measured in accordancewith ISO178 is 7500 MPa or more; and

a value of (tensile fracture stress—65) (MPa)/glass filler ratio (mass%) is 2.90 or more.

[3]

The polyacetal resin composition according to [2], wherein when themolded article formed of the polyacetal resin composition by molding isfractured by application of tensile force, the surface of the glassfiller (B) protruding from a fractured surface of a fractured moldedarticle is covered with a component containing the polyacetal resin (A)having an average thickness of 0.2 μm or more and 3.0 μm or less.

[4]

The polyacetal resin composition according to any one of [1] to [3],further containing a polyethylene resin (C) having a weight-averagemolecular weight of 500,000 or less in an amount of 0.5 parts by mass ormore and 8 parts by mass or less based on 100 parts by mass of thepolyacetal resin (A).

[5]

The polyacetal resin composition according to [4], wherein thepolyethylene resin (C) having a weight-average molecular weight of500,000 or less has a melting point of 115° C. or less.

[6]

The polyacetal resin composition according to any one of [1] to [5],wherein at least one acid is contained as a material having a functionof modifying the surface of the glass filler (B).

[7]

The polyacetal resin composition according to [6], wherein the acid iscarboxylic acid.

[8]

The polyacetal resin composition according to any one of [1] to [7],wherein the polyacetal resin (A) contains a block component.

[9]

The polyacetal resin composition according to [8], wherein the blockcomponent is a hydrogenated polybutadiene component.

[10]

A molded article obtained by molding the polyacetal resin compositionaccording to any one of [1] to [9].

[11]

The molded article according to [10], wherein a polyethylene resin (C)having a weight-average molecular weight of 500,000 or less iscontained; an amount of the polyethylene resin (C) having aweight-average molecular weight of 500,000 or less in a surface layer ofthe molded article is larger than an amount of the polyethylene resin(C) having a weight-average molecular weight of 500,000 or less in alayer surface deeper than 1,000 μm from the surface layer of the moldedarticle as measured by cutting out the layer.

[12]

A method for preparing the polyacetal resin composition according to anyone of [1] to [9], comprising

a step of modifying a surface of the glass filler (B) with a substancecontaining at least one acid and having a function of modifying thesurface of the glass filler (B), and

a step of mixing the glass filler modified and the polyacetal resin (A).

Advantageous Effects of Invention

According to this invention, it is possible to provide a resincomposition from which a molded article having high durability, slidingproperty and wear resistance can be produced with a high productivity.

BRIEF DESCRIPTION OF DRAWING

FIG. 1 The FIGURE shows the relationship between tensile fracture stress(MPa) and glass filler ratio (mass %).

DESCRIPTION OF EMBODIMENTS

Now, an embodiment (hereinafter referred to as “the embodiment”) forcarrying out the invention will be more specifically described. Thefollowing embodiment is just an example for explaining the presentinvention and should not be construed as limiting the present inventionto the following contents. The present invention can be modified invarious ways and carried out within the scope of the invention.

[Polyacetal Resin Composition]

The polyacetal resin composition of the embodiment is a polyacetal resincomposition containing 100 parts by mass of a polyacetal resin (A) and10 parts by mass or more and 100 parts by mass or less of a glass filler(B), in which when a molded article formed of the polyacetal resincomposition by molding is fractured by application of tensile force, thesurface of the glass filler (B) protruding from a fractured surface of afractured molded article is covered with a component containing thepolyacetal resin (A) having an average thickness of 0.2 μm or more and3.0 μm or less.

In the embodiment, the content of the glass filler (B) based on 100parts by mass of the polyacetal resin (A) is 10 parts by mass or moreand 100 parts by mass or less.

If the content is 10 parts by mass or more, mechanical strength andcreep resistance are improved.

In contrast, if the content is 100 parts by mass or less, mutual contactbetween glass filler during molding can be avoided to suppress thefracture of the glass filler. Because of this, mechanical strength andcreep resistance are improved. Further, if the content is 100 parts bymass or less, extrusion molding can be stably performed and poorappearance of the resultant molded article can be suppressed.

The lower limit value of the content is preferably 12 parts by mass,more preferably 15 parts by mass, further preferably 20 parts by massand further more preferably 25 parts by mass.

The upper limit value of the content is preferably 90 parts by mass,more preferably 80 parts by mass, further preferably 75 parts by massand further more preferably 70 parts by mass.

In the embodiment, if a molded article formed of the polyacetal resincomposition by molding is fractured by application of tensile force, theaverage thickness of a component containing the polyacetal resincomposition covering the surface of the glass filler (B) protruding froma fractured surface of a fractured molded article is 0.2 μm or more and3.0 μm or less.

If the average thickness is 0.2 μm or more, creep resistance andmechanical strength are improved. In addition, generation of chips issuppressed and the poor appearance of the molded article to be obtainedcan be suppressed, with the result that the quality thereof improves. Inaddition, since a molding cycle can be shortened, productivity isimproved.

In contrast, if the average thickness is 3.0 μm or less, the flowabilityof the polyacetal resin composition can be suppressed from decreasingand the poor appearance of the molded article can be suppressed.

The lower limit value of the average thickness is preferably 0.3 μm andmore preferably 0.4 μm.

The upper limit value of the average thickness is preferably 2.5 μm andmore preferably 2.0 μm.

In the embodiment, the tensile fracture of the molded article is carriedout by using small tensile-test pieces of a molded article according toISO294-1 obtained by injection molding of a polyacetal resincomposition, at a tension rate of 50 mm/min.

In the embodiment, in a molded article having an arbitrary shape, theaverage thickness of the component containing the polyacetal resincomposition covering the surface of the glass filler (B) may be obtainedby using small tensile-test pieces of a molded article, which arereprocessed by hot press from the molded article having an arbitraryshape.

The hot press for reprocessing a molded article into small tensile-testpieces is carried out at a temperature of 220° C. or less within 5minutes. In this manner, the molded article can be reprocessed withoutaffecting the average thickness of the component containing thepolyacetal resin composition covering the surface of the glass filler(B).

In the case where a molded article having an arbitrary shape cannot bereprocessed into small tensile-test pieces depending upon e.g., the sizeand shape of the molded article, the molded article having an arbitraryshape may be directly used for measurement of tensile fracture stress.

In the embodiment, the average thickness of the component containing thepolyacetal resin composition covering the surface of the glass filler(B) (which protrudes from a fracture surface of the molded articlefractured by application of tensile force) can be obtained throughobservation of a fracture surface of the molded article fractured byapplication of tensile force by a scanning electron microscope (SEM).

Now, a method for obtaining an average thickness will be morespecifically described by taking a glass fiber as an example of theglass filler (B); however, the method is not particularly limited tothis.

In the embodiment, in obtaining the average thickness of the componentcontaining the polyacetal resin composition covering the surface of aglass fiber, it is preferable to select glass fibers present near thecenter of a fracture surface of a molded article fractured byapplication of tensile force as the glass fibers to be used.

First, 50 glass fibers protruding from a fracture surface are selectedat random. Next, the layer covering the surface of each of the glassfibers is observed and the thickness of the layer is measured. If thethickness of the layer is not uniform, a maximum value is employed asthe thickness of the layer. The thickness values of 50 layers arearithmetically averaged to computationally obtain the average thickness.

If the surface of a glass fiber is uniformly covered with the resincomponent, there are some cases where the boundary between the glassfiber and the layer covering the surface thereof is not clear. In thiscase, the diameter of a single glass fiber may be used in calculatingthickness. For example, in the case where the surface of the glass fiberhaving a circular cross-section is uniformly covered with a resincomponent, the thickness of the layer covering the surface is obtainedin accordance with the following expression:Thickness of layer covering the surface=(diameter of glass fiberincluding the layer−diameter of a glass fiber alone)/2

The diameter of the glass fiber alone can be obtained by measuring theremaining matter after the resin component is removed from the moldedarticle.

Examples of the method for removing a resin component from a moldedarticle include a method involving burning the resin component in themolded article at a sufficiently high temperature (400° C. or more); anda method involving removing the resin component in the molded article bysoaking it in a solvent dissolving the polyacetal resin (A).

In the embodiment, it is preferable that the surface of the glass filler(B) is covered with a component containing a polyacetal resin (A), in anarea ratio of preferably 50% or more, more preferably 70% or more,further preferably 80% or more and further more preferably 90% or more.

If the area ratio is 50% or more, the creep resistance of a moldedarticle is more improved.

To cover the surface of the glass filler (B) with a component containingthe polyacetal resin composition and having an average thickness 0.2 μmor more and 3.0 μm or less, for example, using a block copolymerdescribed later as the polyacetal resin (A) and using a substancecontaining an acid described later as the substance (hereinaftersometimes referred to as a “film-forming agent”) having a function ofmodifying the surface of the glass filler (B), are mentioned.

Of them, if a block copolymer and a film-forming agent containing anacid are used in combination, the interface adhesion between apolyacetal resin (A) and a glass filler (B) is dramatically improved andthe average thickness of the component containing the polyacetal resincomposition covering the surface of the glass filler (B) is increased.

In order to control the average thickness to fall within the aboverange, in preparing the polyacetal resin composition by melt-kneading,it is effective to knead the glass filler (B) with the polyacetal resin(A) for a longer time. It is generally considered that a glass filler isdesirably kneaded for a time period as short as possible inmelt-kneading of a resin composition; however, an opposite tendency isobserved for the embodiment. More specifically, in supplying the glassfiller (B) from a side feeder during extrusion kneading, the glassfiller (B) may be supplied from a further upstream side.

In the embodiment, a component containing a polyacetal resin compositionconstituting the layer covering the surface of the glass filler (B)contains the polyacetal resin (A) as a main component and may be a resincomponent containing a polyethylene resin (C) having a weight-averagemolecular weight of 500,000 or less and/or e.g., a stabilizer.

The polyacetal resin composition of the embodiment is a polyacetal resincomposition containing 100 parts by mass of a polyacetal resin (A) and10 parts by mass or more and 100 parts by mass or less of a glass filler(B), in which the tensile fracture stress of a molded article obtainedby molding the polyacetal resin composition and measured in accordancewith ISO527-1 is 135 MPa or more; the bending elastic modulus of themolded article measured in accordance with ISO178 is 7500 MPa or more;and the value of (tensile fracture stress—65) (MPa)/glass filler ratio(mass %) is 2.90 or more.

In the embodiment, the content of the glass filler (B) based on 100parts by mass of the polyacetal resin (A) is 10 parts by mass or moreand 100 parts by mass or less.

If the content is 10 parts by mass or more, mechanical strength andcreep resistance are improved.

In contrast, if the content is 100 parts by mass or less, mutual contactbetween glass filler during molding can be avoided to suppress thefracture of the glass filler. Because of this, mechanical strength andcreep resistance are improved. In addition, flowability is improved.Thus, extrusion molding can be stably performed and the poor appearanceof the molded article can be suppressed.

The lower limit value of the content is preferably 12 parts by mass,more preferably 15 parts by mass, further preferably 20 parts by massand further more preferably 25 parts by mass.

The upper limit value of the content is preferably 90 parts by mass,more preferably 80 parts by mass, further preferably 75 parts by massand further more preferably 70 parts by mass.

In the embodiment, the tensile fracture stress measured in accordancewith ISO527-1 of a molded article obtained by molding the polyacetalresin composition is 135 MPa or more.

The tensile fracture stress is preferably 140 MPa or more, morepreferably 145 MPa or more, further preferably 150 MPa or more andfurther more preferably 155 MPa or more.

In the embodiment, the bending elastic modulus of a molded articleobtained by molding the polyacetal resin composition and measured inaccordance with ISO178 is 7500 MPa or more.

The bending elastic modulus is preferably 8000 MPa or more, morepreferably 8500 MPa or more, further preferably 9000 MPa or more andfurther more preferably 9500 MPa or more.

If a molded article has a tensile fracture stress of 135 MPa or more anda bending elastic modulus of 7500 MPa or more, the molded article canfind a use requiring higher mechanical strength.

If a molded article has a bending elastic modulus of 7500 MPa or more,the thickness of the molded article can be reduced, successfullyattaining size and weight reduction of parts.

In the embodiment, the tensile fracture stress and bending elasticmodulus of a molded article are measured by using small tensile-testpieces of a molded article, which are obtained by injection molding of apolyacetal resin composition in accordance with ISO294-1.

In the embodiment, the tensile fracture stress and bending elasticmodulus of a molded article having an arbitrary shape are obtained byusing small tensile-test pieces of a molded article reprocessed by hotpress from the molded article having an arbitrary shape.

The hot press for reprocessing a molded article into small tensile-testpieces, is carried out at a temperature of 220° C. or less within 5minutes to obtain the molded article reprocessed.

In the case where a molded article having an arbitrary shape cannot bereprocessed into small tensile-test pieces depending upon e.g., the sizeand shape of the molded article, the molded article having an arbitraryshape may be directly used for measurement of tensile fracture stressand bending elastic modulus.

The tensile fracture stress of a molded article is measured by a tensiletest performed in accordance with ISO527-1 at a tension rate of 5mm/min.

The bending elastic modulus of a molded article is measured by a bendingtest performed in accordance with ISO178.

In the embodiment, the value of (tensile fracture stress—65) (MPa)/glassfiller ratio (mass %) is 2.90 or more, preferably 2.95 or more, morepreferably 3.00 or more and further preferably 3.05 or more.

The upper limit value of the value of (tensile fracture stress—65)(MPa)/glass filler ratio (mass %), which is not particularly limited, ispreferably 4.00 or less and more preferably 3.75 or less.

The value of (tensile fracture stress—65) (MPa)/glass filler ratio (mass%) shows contribution of the glass filler (B) per unit blending ratiocontained in a polyacetal resin composition to improvement of tensilefracture stress.

The value of (tensile fracture stress—65) (MPa)/glass filler ratio (mass%) being 2.90 or more means that, in FIG. 1 which is obtained byplotting the ratio of the glass filler on the abscissa axis and tensilefracture stress on the ordinate axis, the relationship between the glassfiller ratio and tensile fracture stress of the polyacetal resincomposition of the embodiment is expressed by the straight line (1)having an intercept 65 MPa and a slope of 2.90 or falls within the areaabove the line.

In the expression, 65 MPa is the value of tensile fracture stress of apolyacetal resin (A) with which the glass filler (B) is not blended. Inthe embodiment, the value of 65 MPa, which is the value of tensilefracture stress of a polyacetal resin (A) with which the glass filler(B) is not blended, rarely changes even if the molecular weight andstructure of the polyacetal resin (A) vary.

In the art, the bending elastic modulus of a polyacetal resin moldedarticle containing a glass filler was improved by increasing the contentof a glass filler. In contrast, tensile fracture stress was unlikely toimprove by adding a glass filler in an amount beyond about 30 mass %(FIG. 1, curve (3)). Because of this, it was difficult to obtain amolded article having a tensile fracture stress of 135 MPa or more.Although the reason for this is not clear, it is conceivable thatadhesiveness of a polyacetal resin to a glass filler is poor and thusfracture may be developed from the interface between them when tensilestress is applied.

A conventional polyacetal resin molded article having low tensilefracture stress in contrast with bending elastic modulus had a problemof insufficient durability. In addition, in melt kneading of thepolyacetal resin composition, deposition, crack of pellets and chipsincrease, with the result that it was difficult to obtain a moldedarticle having good appearance. Likewise, there is a problem inmanufacturing.

In the polyacetal resin composition of the embodiment, adhesion betweena polyacetal resin and a glass filler can be dramatically enhanced.Because of this, even if the content of glass filler increases, thetensile fracture stress of a molded article goes up (FIG. 1, curve (2))without reaching a plateau (FIG. 1, curve (3)). If the value of (tensilefracture stress—65) (MPa)/glass filler ratio (mass %) is a value of 2.90or more, even if stress is repeatedly applied to a molded article,embrittlement of the molded article is suppressed and durability isdrastically improved.

Surprisingly, the polyacetal resin composition having a value of(tensile fracture stress—65) (MPa)/glass filler ratio (mass %) of 2.90or more produces deposition (resin and glass filler deposited around thedies) during melt-kneading of the polyacetal resin composition, but theamount of deposition is low and crack of pellets and the amount of chipsalso low. Owing to this, a molding cycle can be improved, leading toimprovement in appearance of a molded article. In addition, an effect ofimproving the sliding property of the molded article can be obtained.

The ratio of a glass filler is the weight ratio of the glass filler (B)based on the polyacetal resin composition and expressed by “mass %”.

The glass filler ratio is obtained by burning a polyacetal resincomposition or a molded article at a sufficiently high temperature (400°C. or more) to remove a resin component, dividing the weight of theresidue obtained by the weight of the polyacetal resin composition ormolded article before burning and multiplying the product by 100.

In the embodiment, in order to obtain a molded article having a tensilefracture stress of 135 MPa or more, a bending elastic modulus of 7500MPa or more, and a value of (tensile fracture stress—65) (MPa)/glassfiller ratio (mass %) of 2.90 or more, for example, (A) using a blockcopolymer described later as the polyacetal resin and (B) using anacid-containing film-forming agent described later for the glass fillerare mentioned.

In particular, if a block copolymer and an acid-containing film-formingagent are used in combination, interface adhesion between the polyacetalresin (A) and the glass filler (B) is dramatically improved and,particularly, tensile fracture stress and the value of (tensile fracturestress—65 MPa) (MPa)/glass filler ratio (mass %) increase.

When a polyacetal resin composition is produced by melt-kneading, it iseffective to knead the glass filler (B) and the polyacetal resin (A) fora longer time in order to increase the value of (tensile fracture stress(MPa)—65 MPa)/glass filler ratio (mass %). It is generally consideredthat a glass filler is desirably kneaded for a time period as short aspossible in melt-kneading of a resin composition; however, an oppositetendency is resulted in the embodiment.

More specifically, in order to increase the value of (tensile fracturestress−65 (MPa))/glass filler ratio (mass %), in supplying the glassfiller (B) from a side feeder during extrusion kneading, the glassfiller (B) may be supplied from a further upstream side.

The polyacetal resin composition of the embodiment is a polyacetal resincomposition containing 100 parts by mass of a polyacetal resin (A) and10 parts by mass or more and 100 parts by mass or less of a glass filler(B). In the composition, it is preferable that the tensile fracturestress according to ISO527-1 of a molded article obtained by molding thepolyacetal resin composition is 135 MPa or more, the bending elasticmodulus of the molded article according to ISO178 is 7500 MPa or more,and the value of (tensile fracture stress−65) (MPa)/glass filler ratio(mass %) is 2.90 or more; and further that when the molded articleformed of the polyacetal resin composition is fractured by applicationof tensile force, the surface of the glass filler (B) protruding from afracture surface of a fractured molded article is covered with acomponent containing the polyacetal resin (A) having an averagethickness of 0.2 μm or more and 3.0 μm or less.

When a molded article formed of the polyacetal resin composition bymolding is fractured by application of tensile force, the averagethickness of a component containing a polyacetal composition coveringthe surface of the glass filler (B) protruding from a fracture surfaceof a fractured molded article is 0.2 μm or more and 3.0 μm or less.

If the average thickness is 0.2 μm or more, creep resistance andmechanical strength are improved. In addition, generation of chips issuppressed and the poor appearance of the molded article to be obtainedcan be suppressed, leading to quality improvement. In addition, since amolding cycle can be shortened, productivity is improved.

In contrast, if the average thickness is 3.0 μm or less, the flowabilityof the polyacetal resin composition can be suppressed from decreasingand the poor appearance of the molded article can be suppressed.

The lower limit value of the average thickness is preferably 0.3 μm andmore preferably 0.4 μm.

The upper limit value of the average thickness is preferably 2.5 μm andmore preferably 2.0 μm.

<Polyacetal Resin (A)>

A polyacetal resin (A) (hereinafter sometimes referred to as a component(A)) that can be used in the polyacetal resin composition of theembodiment will be more specifically described below.

Examples of the polyacetal resin (A) that can be used in the embodimentinclude a polyacetal homopolymer, a polyacetal copolymer, a polyacetalcopolymer having a crosslinked structure, a block copolymer based on ablock component-containing homopolymer and a block copolymer based on ablock component-containing copolymer.

Polyacetal resins serving as the polyacetal resin (A) may be used singlyor in combination of two or more.

As the polyacetal resin (A), e.g., a combination of polyacetal resinsdifferent in molecular weight and a combination of polyacetal copolymerdifferent in the content of comonomers can be appropriately used.

In the embodiment, as the polyacetal resin (A), a block copolymer ispreferably included.

Examples of the polyacetal resin (A) include a polyacetal homopolymer,which substantially consists of oxymethylene units alone, obtained byhomopolymerization of a cyclic oligomer of formaldehyde, such as aformaldehyde monomer or a trimer (trioxane) or a tetramer (tetraoxane)thereof; and a polyacetal copolymer obtained by copolymerization of acyclic oligomer of formaldehyde, such as a formaldehyde monomer or atrimer (trioxane) or a tetramer (tetraoxane) thereof and a cyclic etheror cyclic formal, such as ethylene oxide, propylene oxide,epichlorohydrin, or a cyclic formal of a glycol or a diglycol such as1,3-dioxolane and 1,4-butanediol formal.

Examples of the polyacetal copolymer that can be used include apolyacetal copolymer having a branched chain obtained bycopolymerization of a monomer of formaldehyde and/or a cyclic oligomerof formaldehyde and a mono-functional glycidyl ether; and a polyacetalcopolymer having a crosslinked structure obtained by copolymerization ofa monomer of formaldehyde and/or a cyclic oligomer of formaldehyde and amultifunctional glycidyl ether.

The polyacetal copolymer may be a block copolymer having a polyacetalrepeating structural unit and a different block (unit).

In the embodiment, as the block copolymer, an acetal homopolymer or anacetal copolymer (hereinafter these will be sometimes collectivelyreferred to as a block copolymer) having at least a block componentrepresented by any one of the following formulas (1), (2) and (3) ispreferable.

In the formulas (1) and (2), R₁ and R₂ each independently represent oneselected from the group consisting of a hydrogen atom, an alkyl group, asubstituted alkyl group, an aryl group and a substituted aryl group; anda plurality of R₁ and R₂ may be mutually the same or different;

R₃ represents one selected from the group consisting of an alkyl group,a substituted alkyl group, an aryl group and a substituted aryl group;

m represents an integer of 1 to 6 and preferably an integer of 1 to 4;and

n represents an integer from 1 to 10000 and preferably an integer of 10to 2500.

The block component represented by the above-mentioned formula (1) is aresidue obtained by removing a hydrogen atom from an alkylene oxideadduct of an alcohol, and the block component represented by the aboveformula (2) is a residue obtained by removing a hydrogen atom from analkylene oxide adduct of a carboxylic acid.

The polyacetal homopolymer having a block component represented by theformula (1) or (2) can be prepared by the method described, for example,in Japanese Patent Laid-Open No. 57-31918.

In the formula (3), R₄ represents one selected from the group consistingof a hydrogen atom, an alkyl group, a substituted alkyl group, an arylgroup and a substituted aryl group; and a plurality of R₄ may bemutually the same or different;

p represents an integer of 2 to 6, two p may be mutually the same ordifferent;

q and r each represent a positive number, assuming that the sum of q andr is 100 mol %, q represents 2 to 100 mol % and r represents 0 to 98 mol%; and —(CH(CH₂CH₃) CH₂)— unit and —(CH₂CH₂CH₂CH₂)— unit are present atrandom or as a block.

The block component represented by any one of the following formulas(1), (2) and (3) may be inserted into a polyacetal resin by reacting acompound constituting a block component having a functional group suchas a hydroxyl group at both or one end, with the terminal portion of apolyacetal during polymerization of the polyacetal.

The insertion amount of a block component represented by the formula(1), (2) or (3) in a block copolymer, which is not particularly limited,is, for example, 0.001 mass % or more and 30 mass % or less based on theblock copolymer as 100 mass %.

To prevent reduction of bending elastic modulus of a molded article, theinsertion amount of the block component is preferably 30 mass % or less.In view of the tensile strength of a molded article, the insertionamount of the block component is preferably 0.001 mass % or more.

The lower limit value of the insertion amount of block component is morepreferably 0.01 mass %, further preferably 0.1 mass % and further morepreferably 1 mass %.

The upper limit value of the insertion amount of block component is morepreferably 15 mass %, further preferably 10 mass % and further morepreferably 8 mass %.

The molecular weight of a block component in a block copolymer ispreferably 10000 or less in order to prevent a reduction of bendingelastic modulus of a molded article, more preferably 8000 or less andfurther preferably 5000 or less.

The lower limit value of the molecular weight of the block component,which is not particularly limited, is preferably 100 or more in order tocontinuously maintain stable sliding property.

Examples of the compound forming a block component in a block copolymerinclude, but are not particularly limited to, C₁₈H₃₇O (CH₂CH₂O)₄₀C₁₈H₃₇,C₁₁H₂₃CO₂ (CH₂CH₂O)₃₀H, C₁₈H₃₇O (CH₂CH₂O)₇₀H, C₁₈H₃₇O (CH₂CH₂O)₄₀H andhydrogenated polybutadiene having two hydroxyalkylated ends.

The block copolymer is preferably an ABA-type block copolymer in view ofcoupling form.

The ABA-type block copolymer refers to a block copolymer having a blockcomponent represented by the formula (3), more specifically, a blockcopolymer constituted by coupling a polyacetal segment A (hereinafterreferred to as A) and a hydrogenated polybutadiene segment B(hereinafter referred to as B) having two hydroxyalkylated ends, in theorder of A-B-A.

The block component represented by the formula (1), (2) or (3) may havean unsaturated bond having an iodine value of 20 g-I₂/100 g or less. Asthe unsaturated bond, which is not particularly limited, a carbon-carbondouble bond is mentioned.

As the polyacetal copolymer having a block component represented by theformula (1), (2) or (3), for example, a polyacetal block copolymerdisclosed in International Publication No. WO 2001/09213 is mentionedand prepared in accordance with the method disclosed in the publication.

Using an ABA type block copolymer as the block copolymer tends toimprove the adhesiveness to the surface of the glass filler (B). As aresult, the tensile fracture stress and bending elastic modulus of amolded article can be likely increased.

The ratio of the block copolymer in the polyacetal resin (A) ispreferably 5 mass % or more and 95 mass % or less based on the wholepolyacetal resin (A) as 100 mass %.

The lower limit value of the ratio of the block copolymer is morepreferably 10 mass %, further preferably 20 mass % and further morepreferably 25 mass %.

The upper limit value of the ratio of the block copolymer is morepreferably 90 mass %, further preferably 80 mass % and further morepreferably 75 mass %.

The ratio of the block copolymer in the resin composition of theembodiment can be measured by e.g., ¹H-NMR and ¹³C-NMR.

<Glass Filler (B)>

Examples of the glass filler (B) (hereinafter sometimes referred to as acomponent (B)) that can be used in the polyacetal resin composition ofthe embodiment include, are not particularly limited to, glass fibers,glass beads and glass flakes.

Examples of the glass fibers include a chopped strand glass fiber, amilled glass fiber and glass fiber roving. Of them, a chopped strandglass fiber is preferable in view of handling and mechanical strength ofa molded article.

As the glass filler (B), glass fillers may be used alone or incombination of two or more.

The form the glass filler (B), such as particle size, fiber diameter andfiber length, is not particularly limited and any form of glass fillermay be used; however, a glass filler (B) having a large surface area ispreferable because the contact area with the polyacetal resin (A) islarge, the creep resistance of the molded article is improved.

In the case of a chopped strand glass fiber, the average fiber diameterthereof is, for example, 7 μm or more and 15 μm or less.

If the average fiber diameter falls within the above range, the surfaceof the molded article becomes smooth, and a decrease in sliding propertycan be prevented. Furthermore, the creep resistance of the moldedarticle can be enhanced; at the same time, the abrasion of the moldsurface during molding can be prevented.

The lower limit value of the average fiber diameter is preferably 8 μmand more preferably 9 μm.

The upper limit value of the average fiber diameter is preferably 14 μmand more preferably 12 μm.

In the embodiment, the average fiber diameter can be easily obtained byburning a molded article at a sufficiently high temperature (400° C. ormore) to remove a resin component, observing the resulting ash by ascanning electron microscope and measuring the diameter. To eliminateerrors, diameters of at least 100 or more chopped strand glass fibersare measured to computationally obtain the average diameter of thefiber.

As the glass fiber, two types or more glass fibers different in diametermay be used in combination.

As the glass filler (B), a glass filler, the surface of which is treatedwith a film-forming agent and modified, is preferable. The film-formingagent is sometimes referred to as a converging agent.

Examples of the film-forming agent include a urethane resin, an epoxyresin, a copolymer resin having at least one acid component. Of them, afilm-forming agent containing a copolymer resin having at least one acidcomponent is preferable.

Examples of the copolymer resin having at least one acid componentinclude a copolymer containing a carboxylic acid-containing unsaturatedvinyl monomer and an unsaturated vinyl monomer except the carboxylicacid-containing unsaturated vinyl monomer as constitution units; and acopolymer containing a carboxylic anhydride-containing unsaturated vinylmonomer and an unsaturated vinyl monomer except the carboxylicanhydride-containing unsaturated vinyl monomer, as constitution units.Of them, a copolymer containing a carboxylic acid-containing unsaturatedvinyl monomer and an unsaturated vinyl monomer except the carboxylicacid-containing unsaturated vinyl monomer as constitution units, is morepreferable.

The film-forming agents may be used alone or in combination of two ormore.

Examples of the carboxylic acid-containing unsaturated vinyl monomerinclude acrylic acid, methacrylic acid, fumaric acid, itaconic acid andmaleic acid, and acrylic acid is preferable.

The carboxylic acid-containing unsaturated vinyl monomers may be usedalone or in combination of two or more.

As the carboxylic anhydride-containing unsaturated vinyl monomer, e.g.,an anhydride such as maleic acid or itaconic acid is mentioned.

The carboxylic anhydride-containing unsaturated vinyl monomers may beused alone or in combination of two or more.

If the surface of the glass filler (B) is modified with a film-formingagent, the adhesion strength of the interface between the glass fillerand the polyacetal resin (A) can be enhanced and the average thicknessof the layer covering the surface of the glass filler is increased.Owing to this, creep resistance and tensile fracture stress areimproved. In addition, wearing at the time of sliding can be suppressed.

In particular, if a polyacetal resin containing a block component and aglass filler modified with a film-forming agent are used in combination,creep resistance and tensile fracture stress are drastically improved.

In the embodiment, the surface of the glass filler (B) may be modifiedwith a coupling agent.

The coupling agent is not particularly limited and a known couplingagent can be used.

Examples of the coupling agent include an organic silane compound, anorganic titanate compound and an organic aluminate compound.

The coupling agents may be used alone or in combination of two or more.

Examples of the organic silane compound include vinyltriethoxysilane,vinyl-tris-(2-methoxyethoxy)silane, γ-methacryloxypropylmethoxysilane,γ-aminopropyltrimethoxysilane, γ-aminopropyltriethoxysilane,N-β-(aminoethyl)-γ-aminopropyltrimethoxysilane,β-(3,4-epoxycyclohexyl)ethyltriethoxysilane,γ-glycidoxypropyltrimethoxysilane and γ-mercaptopropyltrimethoxysilane.

Of them, vinyltriethoxysilane, vinyl-tris-(2-methoxyethoxy)silane,γ-methacryloxypropylmethoxysilane, γ-aminopropyltrimethoxysilane,γ-aminopropyltriethoxysilane and γ-glycidoxypropylmethoxysilane arepreferable. Vinyltriethoxysilane, γ-glycidoxypropyltrimethoxysilane andγ-aminopropyltriethoxysilane are more preferable in view of economy andthermal stability of the resin composition.

Examples of the organic titanate compound include tetra-i-propyltitanate, tetra-n-butyl titanate, a butyl titanate dimer, tetrastearyltitanate, triethanolamine titanate, titanium acetylacetonate, titaniumlactate, octylglycol titanate and isopropyl(N-aminoethylaminoethyl)titanate.

Examples of the organic aluminate compound include acetoalkoxyaluminumdiisopropylate.

If a glass filler the surface of which is treated with a coupling agentis used, the creep resistance of a molded article tends to be moreimproved; at the same time, the thermal stability of the molded articletends to be more improved.

<Polyethylene Resin (C) Having a Weight-Average Molecular Weight of500,000 or Less>

In the resin composition of the embodiment, a polyethylene resin (C)having a weight-average molecular weight of 500,000 or less (hereinaftersometimes referred to as a polyethylene resin (C) or a component (C)) ispreferably contained.

As the polyethylene resin (C), polyethylene resins may be used alone orin combination of two or more.

If the weight-average molecular weight is 500,000 or less, thegeneration of chips can be suppressed; at the same time, coefficient offriction in sliding between a molded article and a metal is low and verystable.

(C) The weight-average molecular weight of a polyethylene resin ispreferably 10,000 or more and 400,000 or less, more preferably 15,000 ormore and 300,000 or less, further preferably 20,000 or more and 200,000or less and further more preferably 30,000 or more and 150,000 or less.

The weight-average molecular weight can be measured by the followingmethod. A sample or molded article of a polyacetal resin composition ispartly cut out and soaked in hexafluoroisopropanol (hereinafterabbreviated to HFIP) and dissolved. The polyacetal resin componentdissolved is filtered off. Note that, when the polyacetal resincomponent is not dissolved in HFIP, the polyacetal resin component maybe removed by decomposition with hydrochloric acid and the like.

Next, the unmolten residual component was dissolved in trichlorobenzene(hereinafter abbreviated to TCB) at 140° C. and filtered. In thismanner, a glass filler is filtered off. The resultant filtrate issubjected to measurement by gel permeation chromatography (hereinafterabbreviated to GPC). As the column, a single column UT-807 (manufacturedby Showa Denko K.K.) and two columns GMHHR-H (S) HT (manufactured byTohso Corporation) are connected in series and put in use. As the mobilephase, TCB is used. A sample is used in a concentration of 20 to 30 mg(polyethylene resin)/20 mL (TCB). Measurement is carried out by settingthe temperature of the columns at 140° C. and the flow rate at 1.0mL/minute, and using a differential refractometer as a detector.

The weight-average molecular weight is calculated withpolymethylmethacrylate (hereinafter abbreviated to PMMA) used as astandard substance. The PMMA standard substance to be used herein isPMMA having a number average molecular weight within the range of about2,000 to 1,000,000, and at least 4 samples are used.

The content of the polyethylene resin (C) based on the polyacetal resin(A) (100 parts by mass) is preferably 0.5 parts by mass or more and 8parts by mass or less, more preferably 1 part by mass or more and 6parts by mass or less and further preferably 1.5 parts by mass or moreand 5 parts by mass or less.

If the content is 0.5 parts by mass or more, sliding property issatisfactory and stable for a long period of time. In addition, wearresistance is improved.

If the content is 8 parts by mass or less, reduction in mechanicalstrength, chips of a resin composition during melt-kneading and peelingof a molded article (removal of a polyethylene resin component (C)) canbe suppressed.

The content of the polyethylene resin (C) can be checked, for example,by the following method. A polyacetal resin composition or a moldedarticle is burned at a sufficiently high temperature (400° C. or more)to remove a resin component. The weight of the resulting ash is measuredto obtain the content of the glass fiber (B).

Next, the polyacetal resin contained in a polyacetal resin compositionor a molded article is decomposed with hydrochloric acid. From theresidue, the blending ratio of the glass fiber (B) is subtracted toobtain the content of the polyethylene resin (C). Note that, dependingupon the situation, the presence or absence of other components ischecked by e.g., IR, and an additional removal operation may be carriedout.

Examples of the polyethylene resin (C) to be used in the embodimentinclude a very low-density polyethylene, a low-density polyethylene, ahigh density polyethylene and a straight-chain low density polyethylene.Furthermore, an ethylene copolymer and the like containing 5 mass % orless of a comonomer such as propylene, butene, and octene may be used.

Of them, a low-density polyethylene is preferable in view of thecoefficient of friction in sliding on a metal.

As the polyethylene resin (C) that can be used in the embodiment, atleast one polyethylene resin having a melting point (hereinafterabbreviated to Tm) of 115° C. or less is preferably contained. Tm ismore preferably 110° C. or less.

If Tm is 115° C. or less, the friction coefficient in sliding on a metalis low and very stable molded article is obtained. In addition, inproducing a polyacetal resin composition by melt-kneading, the torque ofthe extruder used in the operation can be efficiently and significantlyreduced. Owing to this, an increase of the discharge amount, which wasdifficult for a conventional composite of a polyacetal resin and a glassfiller, can be attained.

In the embodiment, as Tm, an endothermic peak value, which is obtainedby subjecting a sample of a polyacetal resin composition or a piece (4to 6 mg) cut out (preferably pressed into a slice) from a moldedarticle, to differential scanning calorimetry (DSC) performed at atemperature increase rate of 10° C./min, is used.

<Stabilizer>

A molded article of the polyacetal resin composition of the embodimentmay contain various types of stabilizers usually used in a polyacetalresin composition as long as the object of the present invention can beattained.

Examples of the stabilizer include, but are not particularly limited to,an antioxidant, and a scavenger for formaldehyde and formic acid and thelike.

The stabilizers may be used alone or in combination of two or more.

As the antioxidant, a hindered phenol antioxidant is preferable in viewof improvement of thermal stability of a molded article. As the hinderedphenol antioxidant, which is not particularly limited, a hindered phenolantioxidant known in the art can be appropriately used.

The addition amount of the antioxidant based on 100 parts by mass of thepolyacetal resin (A) is preferably 0.1 part by mass or more and 2 partsby mass or less.

Examples of the scavenger for formaldehyde and formic acid include acompound containing formaldehyde-reactive nitrogen such as melamine anda polyamide resin and the like and a polymer thereof; and a hydroxide,an inorganic acid salt, and a carboxylic acid salt of an alkali metal oran alkaline earth metal.

Specific examples thereof include calcium hydroxide, calcium carbonate,calcium phosphate, calcium silicate, calcium borate and fatty acidcalcium salts (calcium stearate, calcium myristate). These fatty acidsmay be substituted with a hydroxyl group.

The addition amount of the scavenger based on 100 parts by mass of thepolyacetal resin (A) is as follows: in the case of a polymer containingformaldehyde-reactive nitrogen, serving as a scavenger for formaldehydeand formic acid, the addition amount thereof is preferably 0.1 part bymass or more and 3 parts by mass or less; and in the case of the fattyacid salt of an alkaline earth metal, the addition amount thereofpreferably falls within the range of 0.1 part by mass or more and 1 partby mass or less.

<Other Components>

The molded article of a polyacetal resin in the embodiment may containcomponents known in the art and used in conventional polyacetal resincompositions as long as the object of the present invention can beattained. Specific examples thereof include a filler other than theglass filler (e.g., talc, wollastonite, mica, calcium carbonate), aconductive agent (e.g., carbon black, graphite, carbon nanotubes), acolorant (e.g., titanium oxide, zinc oxide, iron oxide, aluminum oxide,organic dyes), a sliding property imparting agent (e.g., various estercompounds, metal salts of organic acids), a stabilizer such as anultraviolet absorber, a light stabilizer and a lubricant.

The addition amounts of the other components are follows: The additionamount of each of the filler except a glass fiber, conductive agent andcolorant based on 100 mass % of the polyacetal resin is preferably 30mass % or less; the addition amount of each of the sliding propertyimparting agent, ultraviolet absorber, light stabilizer and lubricantbased on 100 mass % of the polyacetal resin is preferably 5 mass % orless.

The other components may be used alone or in combination of two or more.

<Method for Producing the Molded Article>

The molded article of the embodiment can be produced by a method knownin the art; more specifically, produced by mixing and melt-kneading theraw material components by a single or multi-screw kneading extruder, aroll or a Banbury mixer and the like, and molding into a shape. Of them,a twin-screw extruder equipped with a pressure reducing device and sidefeeder is preferably used.

As a method for mixing and melt-kneading the raw material components,which is not particularly limited, a method known to those skilled inthe art can be used. Specific examples thereof include a methodinvolving mixing a component (A) and a component (B) in advance by asuper mixer, a tumbler or a v-shaped blender and the like and subjectingthe mixture to simultaneous melt-kneading by a twin-screw extruder; anda method involving supplying a component (A) to a twin-screw extruderthrough the main throat portion and melt-kneading, and adding acomponent (B) through the mid-portion of the extruder during themelt-kneading. Both methods may be used; however, in order to improvethe mechanical properties of the molded article of the embodiment, themethod involving supplying a component (A) to a twin-screw extruderthrough the main throat portion and melt-kneading, and adding acomponent (B) through the mid-portion of the extruder during themelt-kneading is preferable. Since optimal conditions vary dependingupon the size of the extruder, it is preferable that the conditions areappropriately controlled within the range available by those skilled inthe art. More preferably, the screw of the extruder is variouslydesigned within the range available by those skilled in the art.

When a component (C) is blended, the component (C) can be added from amid-portion of the extruder; however, it is preferably supplied throughthe main throat portion. In such a process, it was surprisingly foundthat the effect of greatly reducing the torque of the extruder can beobtained. Likewise, the productivity can be greatly improved.

In the embodiment, as a method for obtaining a molded article, which isnot particularly limited, a molding method known in the art can be used.Specifically, molding can be made by any one of the molding methodsincluding extrusion molding, injection molding, vacuum molding, blowmolding, injection compression molding, decorative molding,different-material molding, gas assist injection molding, foam injectionmolding, low pressure molding, ultra-thin wall injection molding(ultra-high speed injection molding) and an in-mold composite molding(insert molding, outsert molding).

<Amount of Polyethylene Resin (C) in the Surface Layer of MoldedArticle>

In the molded article of the embodiment, the amount of polyethyleneresin (C) having a weight-average molecular weight of 500,000 or lesspresent in the surface layer of the molded article is preferably largerthan the amount of polyethylene resin (C) having a weight-averagemolecular weight of 500,000 or less in the layer surface deeper than1,000 μm from the surface layer of the molded article measured byexcising out the layer.

The amount of polyethylene resin (C) is computationally obtained fromrelative elemental concentration (atomic %) of carbon C measured byX-RAY photoelectron spectroscopy (XPS). As a measuring device, forexample, ESCALAB250 and the like manufactured by Fisher Scientific maybe mentioned.

As the excitation source for measurement, e.g., monoAlKα is used. Toremove the influence of contaminants attached to the surface of a moldedarticle, the surface of the molded article is ultrasonically washed witha cleaner (for example, aqueous solution of VALTRON DP97031), rinsedwith pure water and dried in e.g., an oven. The take-off angle ofphotoelectrons is set at 0° (perpendicular to the molded article). Inthe capture area, Surbey Scan is carried out at 0 to 1100 eV, and NarrowScan is targeted to a carbon C (1s) region. Furthermore, in Pass Energyat Survey scan is 100 eV and that of Narrow scan is 20 eV. In XPSmeasurement, Binding Energy of 286 to 288 eV represents carbon derivedfrom a polyacetal resin and Binding Energy of 284 to 286 eV representscarbon derived from the olefin such as polyethylene. If the peaks can beseparated, only carbon derived from polyethylene is used. If the peakscannot be separated, the peak area within the range of 284 to 288 eV maybe used.

Assuming that the carbon concentration in the surface layer of a moldedarticle is represented by C₁ and the carbon concentration in the layersurface of the molded article deeper than 1,000 μm and measured byexcising the molded article and taking out the center, is represented byC₂, if the relationship represented by the expression: [C₁]/[C₂]>1 isestablished, it can be said that the amount of polyethylene resin (C)having a weight-average molecular weight of 500,000 or less) present inthe surface layer of the molded article is larger than the amount ofpolyethylene resin (C) having a weight-average molecular weight of500,000 or less in the layer surface (measured by excising it out)deeper than 1,000 μm from the surface layer of the molded article.

Note that, in the embodiment, as the site at which C₂ is to be measured,a site deeper than 1,000 μm is defined; however, in the molded articleobtained by molding the polyacetal resin composition of the embodiment,as long as a site is present at a level deeper than 100 μm from thesurface layer thereof, the amount of polyethylene resin (C) present atthe site is almost the equal to the starting amount thereof.

It is preferable that 1.01≤[C₁]/[C₂]≤1.20, more preferable that1.02≤[C₁]/[C₂]≤1.18 and further preferable that 1.05≤[C₁]/[C₂]≤1.15.

Note that, if a block copolymer having a block component represented bythe above formula (3) is used as the polyacetal resin, the carbonconcentration of the polyacetal resin, itself increases. However, sincethe concentration of carbon derived from a polyacetal resin in thesurface layer does not differ from that at the site deeper than 1,000μm, if the above expression is established, it can be said that a largeramount of polyethylene resin (C) is present in the surface layer.

Since a polyethylene resin (C) is present in a larger amount in thesurface layer of the molded article than in a site deeper than 1,000 μm,the sliding property at the initiation time of sliding is improved.Furthermore since the effect on a sliding property can be dramaticallyimproved by adding a small amount of polyethylene, reduction ofmechanical strength such as bending elastic modulus can be suppressed.Moreover, an extraordinary effect of suppressing the amount of chipsduring melt-kneading of a resin composition can be obtained.

Note that, in the case of a molded article having a thickness of lessthan 2,000 μm, the carbon concentration of the molded article at thecenter in the depth direction can be used in place of the carbonconcentration of a layer deeper than 1,000 μm,

To attain the amount of the polyethylene resin (C) in the surface layerof a molded article to be larger than that in a layer deeper than 1,000μm, the weight-average molecular weight of the polyethylene resin (C) tobe blended is controlled to fall within the range of a 500,000 or less.Furthermore, the amount of the polyethylene resin (C) in the surfacelayer of a molded article is controlled to be present in a larger amountthan a layer deeper than 1,000 μm by setting Tm of the polyethyleneresin (C) to be 115° C. or less.

[Use]

The polyacetal resin composition of the embodiment can be used as a rawmaterial for a molded article requiring durability, mechanical strengthand wear resistance.

The molded article of the embodiment can be suitably used as automotiveparts, in particular, suitably used as parts playing a role of a gearand a pulley in contact with other members.

Other than these, the molded article can be applied to uses known as theuses of a polyacetal resin in the art. Examples thereof includemachinery parts such as cams, sliders, levers, arms, clutches, feltclutches, idler gears, rollers, key stems, key tops, shutters, reels,shafts, joints, shafts, bearings, door rollers and guides; resin partsof outsert molding, resin parts of insert molding, chassis, tray, sideplate, auto parts; door associated parts such as door locks, doorhandles, window regulators, window regulator wire drums, speaker grillsand glass holders; seat belt associated parts such as slip rings forseat belts, and press buttons; parts such as combination switch parts,switches, clips; fuel associated parts such as gasoline tanks, fuel pumpmodules, valves, and gasoline tank flanges; parts for office automationequipment such as printers and copiers; parts for video equipment suchas digital video cameras and digital cameras; CD, DVD, Blu-ray Disc,other optical disc drives; music, video or information devices such asnavigation systems and mobile personal computers; parts forcommunication equipment such as mobile phones and facsimiles; parts forelectrical equipment; and parts for electronics. Examples of other usesinclude nibs of the writing instruments, and parts of machinery ofpushing in and out lead; wash basins, drain outlets, drain plugopen-shut machinery parts; code stoppers for clothing, adjusters andbuttons; watering nozzle, watering hose connection joints; stairhandrail parts, and building supplies such as support tools for floormaterials; toys, fasteners, chains, conveyors, buckles, sportsequipment, vending machines (open-shut locking mechanism, commoditydischarge machinery parts), furniture, musical instruments, andhousehold equipment parts.

EXAMPLES

The embodiment will be more specifically described by way of Examplesand Comparative Example; however, the embodiment is not limited by theseExamples and Comparative Examples as long as it is not outside thescope.

Production conditions and evaluation items of polyacetal resincompositions and molded articles used in Examples and ComparativeExamples are as follows.

(1) Extrusion

A co-rotating twin-screw extruder (TEM-48SS extruder manufactured byTOSHIBA MACHINE CO., LTD) having a ratio of screw length L to screwdiameter D (L/D ratio) of 48 (the number of barrels 12); side feeders ata sixth barrel and an eighth barrel and a vacuum vent at an eleventhbarrel, was used. The first barrel was cooled with water; thetemperatures of second to fifth barrels were set at 210° C.; and thetemperatures of sixth to twelfth barrels were set at 180° C.

The screw used for extrusion were designed as follows. Flight screws(hereinafter, abbreviated to FS) were arranged at the first to fourthbarrels. At the fifth barrel, two kneading discs (hereinafterabbreviated to RKD) having a feed function; two kneading discs(hereinafter abbreviated to NKD) having no feed function; and a singlekneading disc (hereinafter abbreviated to LKD) having a feed function inthe reverse direction were arranged in this order. FS was arranged atthe sixth to eighth barrels; a single RKD and a single NKD were arrangedin this order at the ninth barrel; and FS was arranged at 10th to 11thbarrels.

(Process 1)

A glass filler was supplied from the side feeder at the sixth barrel andextrusion was performed at a screw rotation speed of 150 rpm and a totalextrusion amount of 70 kg/h.

(Process 2)

A glass filler was supplied from a side feeder at the eighth barrel andextrusion was performed at a screw rotation speed of 150 rpm and a totalextrusion amount of 70 kg/h.

(2) Extrusion Productivity

The torque at the time of the extrusion was used for evaluation ofextrusion productivity.

As the numerical value of torque becomes smaller, the extrusion waseasily made and the discharge speed can be sufficiently increased; andextrusion productivity is determined to be high.

(3) Deposition Amount

Substances deposited near the dice during extrusion were collected andquantified per unit time.

As the deposition amount is lower, the productivity and quality are morefavorable.

(4) Amount of Chips

After the extrusion mentioned above, a strand of 80° C. was loaded in astrand cutter having a clearance of 7/1000 and pelletized. The pelletswere not passed through a pellet sorting machine.

The resultant pellets of 1 kg±0.1 kg were passed through a 14-mesh sievein three divided doses. The weight of pellets passed through the mesh isdivided by the weight of initial pellets subjected to sieving to obtainthe amount of chips. The smaller the value, the smaller the amount ofchips and the better the quality.

(5) Small Tensile-Test Pieces of a Molded Article

Molding is carried out by using an injection molding machine (EC-75NII,manufactured by TOSHIBA MACHINE CO., LTD) in injection conditions: acylinder temperature of 205° C., injection time of 35 seconds andcooling time of 15 seconds, to obtain small tensile-test pieces of amolded article according to ISO294-2. The temperature of a mold was setat 90° C. and the small test-pieces of a molded article according toISO294-2 were used the following individual measurements (6) to (8),(10), (12) and (14).

As the test pieces for creep resistance test to be used in measurementof the creep rupture time (9) below, small tensile-test pieces of amolded article according to JIS K7139-5A were obtained. The temperatureof a mold was set at 90° C.

(6) Tensile Fracture Stress

Using the molded article obtained in the above section (5), a tensiletest was performed in accordance with ISO527-1 and at a tension rate of5 mm/min, and then, tensile fracture stress was measured.

(7) Bending Elastic Modulus

Using the molded article obtained in the above section (5), a bendingtest was performed in accordance with ISO178, and bending elasticmodulus was measured.

(8) Average Thickness of a Component Covering the Surface of the GlassFiller

The molded article obtained in the above section (5) was fractured in atensile test at a tension rate 50 mm/min. To the fracture surface of themolded article, platinum was deposited to prepare observation testpieces. The observation test pieces were subjected to measurement undera scanning electron microscope (SEM). The (observation) magnificationwas 5,000×.

Control was made so as to observe the centers of fracture surface ofobservation test pieces as an observation site. From glass fibersprotruding from the fracture surface, 50 glass fibers were arbitrarilyselected. It was confirmed that the surfaces of the all glass fibershaving a circular cross-section were each covered with a resincomponent. Next, the diameters of the glass fibers covered with theresin component were measured. Separately, the test pieces were burnedat 450° C. for 3 hours to remove the resin component, and then, theaverage diameter of 100 glass fibers was previously obtained. Based onthe difference in diameter between both cases, the thickness of theresin component deposited to the surface was obtained. The thicknessvalues of 50 glass fibers were arithmetically averaged and regarded asan average thickness of the component covering the surface of the glassfiller.

(9) Creep Rupture Time

The creep resistance test pieces of a molded article obtained in theabove section (5) were subjected to a creep test using a creep tester(manufactured by TOYO SEIKI SEISAKU-SHO, LTD.) in the environment of 80°C. and at a load of 25 MPa. The time until the test pieces were brokenwas measured. Measurement was performed three times and the average ofthem was regarded as creep rupture time. The larger the numerical value,the more excellent the creep resistance.

(10) Wear Resistance (Depth of Wear) Against SUS304 Ball and DynamicFriction Coefficient Against SUS304 Ball

The molded article obtained in the above section (5) was subjected to aball-on-disc reciprocating frictional abrasion tester (Type AFT-15MS,manufactured by Toyo Seimitsu). A sliding test was performed under theenvironment of 23° C. and a humidity of 50% in the conditions: a load of19.6 N, a linear velocity of 30 mm/sec, a reciprocation distance of 20mm and a reciprocation number of 5,000. As the ball, SUS304 ball (havinga diameter of 5 mm) was used. The wear volume of the sample (depth ofwear) after the sliding test was measured by a confocal microscope(OPTELICS (registered trademark) H1200, manufactured by LasertecCorporation). The measurement values (n=5) were averaged and specifiedas the depth of wear by SUS304 ball. The lower the numeric value, themore excellent the wear resistance.

In the sliding test, the dynamic friction coefficient at the time whensliding was performed 1000 times was specified as dynamic frictioncoefficient (initial sliding property) against SUS304 ball, the dynamicfriction coefficient at the time when sliding was performed 5,000 timeswas specified as the dynamic friction coefficient of a molded articleagainst SUS304 ball. The lower the numeric value, the more excellent thesliding property.

(11) Dynamic Friction Coefficient Against SS400 Flat Plate

A resin pin having a round tip of 5 mm was manufactured by molding byuse of an injection molding machine (Ti30G2, manufactured by ToyoMachinery & Metal Co., Ltd.) in injection conditions: a mold temperatureof 90° C., a cylinder temperature of 200° C., an injection speed of 40%and injection time for 3 seconds.

A ball-on-disc reciprocating dynamic frictional abrasion tester (TypeAFT-15MS, manufactured by Toyo Seimitsu) was used. Evaluation wasperformed in the environment of 23° C. and a humidity of 50% and in theconditions: a load of 39.2 N, a linear velocity of 30 mm/sec, areciprocation distance of 20 mm and reciprocation times of 10,000, byusing SS400 flat metal plate as a disc and a resin pin having a roundtip of 5 mm in diameter as a ball. The dynamic friction coefficient atthe time when sliding was performed 10,000 times was specified as thedynamic friction coefficient of the molded article against SS400 flatplate. The lower the numeric value, the more excellent the slidingproperty.

(12) Dynamic Friction Coefficient Between the Same Materials

The ball-on-disc reciprocating dynamic frictional abrasion tester (TypeAFT-15MS, manufactured by Toyo Seimitsu) was used. Evaluation wasperformed in the environment of 23° C. and a humidity of 50% and in theconditions: a load of 19.6 N, a linear velocity of 30 mm/sec, areciprocation distance of 20 mm and reciprocation times of 5,000, byusing the molded article obtained in the above section (5) as a disc anda resin pin having a round tip of 5 mm in diameter obtained in the abovesection (11) as a ball. The dynamic friction coefficient at the timewhen sliding was performed 5,000 times was specified as the dynamicfriction coefficient of the same molded article materials. The lower thenumeric value, the more excellent the sliding property.

(13) Molding Cycle

A spur gear (single) having a module of 0.8, teeth number of 50 and atooth width of 5 mm was molded by using an injection molding machine(α50i-A, manufactured by FANUC CORPORATION) by setting the cylindertemperature at 190° C., the mold temperature at 80° C. and the injectionpressure at 120 MPa. At this time, the injection time was set at 5seconds and the cool time was set at 15 seconds as a minimum. If thetime required for measuring the amount of resin exceeded 15 seconds, thescrew rotation speed was increased to shorten the measurement time. Ifthe measurement time exceeded 15 seconds even if the screw rotationspeed was increased during measurement time, cooling time was set atmeasurement time+3 seconds. Under the conditions, continuous molding wascarried out for 20 minutes.

In this test, the length of the cooling time per sample and the numberof gears molded during continuous molding per 20 minutes were measuredand used as evaluation criteria for molding productivity. At this time,if the measurement time is long (in some cases, cool time is also long),the time required for one shot becomes long, with the result that themolding cycle becomes long and productivity decreases.

(14) Ratio of Polyethylene Resin (Surface Polyethylene Ratio) Present inSurface Layer of the Molded Article

An X-ray photoelectron spectroscope (XPS) ESCALAB250, manufactured byThermo Fisher Scientific Inc., was used and monoALKα (15 kV×10 mA) wasused as an excitation source. An area size of 1 mm squares was used foranalysis. Deposited substances on the surface layer of a molded articlewas removed as follows. After the organic substances of the surface wasremoved with a 1.5% aqueous solution of a commercially availableprecision equipment cleaning agent (VALTRON DP97031) by ultrasoniccleaning in the condition of 50° C. for 3 minutes, an ultrasonictreatment with distilled water for high performance liquidchromatography was performed at room temperature for 15 minutes forwashing. Subsequently, the sample ultrasonically washed was dried in adry oven of 80° C. for one hour and then subjected to measurement. Inthe measurement, the take-off angle of photoelectrons was set at 0°(perpendicular to the molded article). In the capture area, Surbey Scanis carried out at 0 to 1100 eV, and Narrow Scan is targeted to a carbonC (1s) region. Furthermore, in Pass Energy at Survey scan is 100 eV andthat of Narrow scan is 20 eV. At this time, the C concentration wasobtained from the peak area ratio in the range of 284 eV to 288 eV. Therelative elemental concentration was calculated from the area ratio androunded. If the concentration is 1 atomic % or more, calculation wasperformed with significant two-digit accuracy; whereas, theconcentration is less than 1 atomic %, calculation was performed with asignificant-digit accuracy. As the measurement sample, the moldedarticle obtained in the above section (5) was used. The carbonconcentration in the surface layer of the molded article was expressedby [C₁]. Subsequently, the center of the molded article in the thicknessdirection was cut out by a microtome and the carbon concentration ofthis portion was measured in the same manner and specified as the carbonconcentration [C₂] near the center in the thickness direction.

(15) Cantilever Bending Vibration Fatigue

Test pieces were prepared by molding a flat plate of 12 cm in length×8cm in width×0.3 cm in thickness by using an injection molding machine(EC-75NII, manufactured by TOSHIBA MACHINE CO., LTD) in the conditions:the cylinder temperature of 200° C. and a mold temperature of 80° C. andcool time of 10 seconds; and cutting the flat plate into test pieces inaccordance with ASTM D671 TYPE1 such that the direction parallel to theresin supply direction during molding became the direction ofmeasurement. The test pieces were subjected to measurement performed bya repeat vibration fatigue tester manufactured by TOYO SEIKI KOGYO CO.LTD. in accordance with the method according to ASTM D671-B at a repeatnumber of 1800 times/min and a temperature of 23° C. The stress (kgf/m²) at the time when a test piece was fractured at the repeat numberof 10⁶ in the bending test or at the time when the maximum deflection ofa test piece exceeds the value before fracture±8 mm was specified as thevalue of the cantilever bending vibration fatigue. From a graph obtainedby plotting at least 5 points of about 10⁴ to 10⁷ repeat times, a valueof 10⁶ repeat times was read out. The larger the value, the moreexcellent the durability.

(16) SFD (Spiral Flow Distance)

SFD of each composition at an injection pressure of 80 MPa was evaluatedby using an injection molding machine (ROBOSHOT α-50iA, manufactured byFANUC CORPORATION) in the conditions: a cylinder temperature of 200° C.,a mold temperature of 80° C., and using an SFD mold of 2 mm inthickness. The longer the SFD, the more excellent the flowability.

The raw material components for polyacetal resin compositions and moldedarticles used in Examples and Comparative Examples will be describedbelow.

(A1) Product name: TENAC (registered trademark)-C 4520 (manufactured byAsahi Kasei Chemicals Corporation), melt flow rate (MFR)=9.0 g/10minutes, number average molecular weight Mn=about 70,000

(A2) Product name: TENAC (registered trademark)-C 7520 (manufactured byAsahi Kasei Chemicals Corporation),

Melt flow rate (MFR)=45.0 g/10 minutes, number average molecular weightMn=25,000

(A3) A polyacetal block copolymer was prepared as follows. Adouble-screw paddle continuous polymerizer equipped with a jacketthrough which a heat medium can be passed was used by controlling thetemperature thereof at 80° C. Polymerization was performed continuouslysupplying trioxane at a rate of 40 moles/hour, 1,3-dioxolane as a cyclicformal at a rate of 2 moles/hour, boron trifluoride di-n-butyl etheratedissolved in cyclohexane as a polymerization catalyst in an amount of5×10⁻⁵ moles per 1 mole of trioxane and hydrogenated polybutadiene(number average molecular weight Mn=2,330) having a hydroxyl group atboth ends represented by the following formula (5) in an amount of1×10⁻³ moles per 1 mole of trioxane as a chain transfer agent, to theabove polymerizer.

Next, the polymer discharged from the polymerizer was put in a 1%aqueous triethylamine solution. After the polymerization catalyst wascompletely deactivated, the polymer was filtered and washed to obtain acrude polyacetal block copolymer.

To 100 parts by mass of the resultant crude polyacetal block copolymer,1 part by mass of an aqueous solution containing a quaternary ammoniumcompound (described in Japanese Patent No. 3087912) was added anduniformly mixed. The addition amount of the quaternary ammonium compoundwas 20 ppm by mass in terms of nitrogen equivalent. The mixture wassupplied to a double-screw extruder with a vent and 0.5 parts by mass ofwater was added to 100 parts by mass of the polyacetal block copolymermolten in the extruder. Unstable terminal portions of the polyacetalblock copolymer were decomposed away by setting the temperature of theextruder to be 200° C. and the retention time in the extruder to be 7minutes.

To the polyacetal block copolymers from which unstable terminal portionswere decomposed away, 0.3 parts by mass of triethyleneglycol-bis-[3-(3-t-butyl-5-methyl-4-hydroxyphenyl)-propionate] was addedas an antioxidant. While removing a solvent from an extruder with a ventat a vacuum degree of 20 Torrs, a strand was extruded from dies portionof the extruder and pelletized.

The polyacetal block copolymer thus obtained was designated aspolyacetal block copolymer (A3). The block copolymer is an ABA typeblock copolymer and the melt flow rate thereof was 15 g/10 minutes(ISO-1133, condition D). The number average molecular weight Mncomputationally obtained from the melt flow rate was about 50,000.

As the glass filler (B), the following fillers were used.

(B1) Glass fiber treated with e.g., a film-forming agent described inJapanese Patent No. 4060831, in Production Example 1 (containing acopolymer containing acrylic acid and methyl acrylate).

(B2) Glass fiber treated with a film-forming agent (containing acopolymer containing acrylic acid) described in Japanese PatentLaid-Open No. 2012-136385, Example 1.

(B3) Glass fiber treated with a film-forming agent (containing no acid)described in Japanese Patent Laid-Open No. 2009-7179, Sample No. 1.

As the polyethylene resin (C), the following resins are used.

(C1) SUNTEC (registered trademark) LD L1850A, manufactured by AsahiKasei Chemicals Corporation weight-average molecular weight: 132,000,Tm=107° C., density: 918 kg/m³

(C2) SUNTEC (registered trademark) HD J240, manufactured by Asahi KaseiChemicals Corporation, weight-average molecular weight: 73,000, Tm=127°C., density: 966 kg/m³

(C3) Sunfine (registered trademark) BM840, manufactured by Asahi KaseiChemicals Corporation weight-average molecular weight: 324,000, Tm=126°C., density: 931 kg/m³

(C4) Sunfine (registered trademark) UH901, manufactured by Asahi KaseiChemicals Corporation

molecular weight (viscosity method): 3,300,000, Tm=136° C., density: 940kg/m³

Weight-average molecular weights were each measured by dissolving apolyethylene resin (C) in TCB at 140° C. and subjecting the obtainedsolution to GPC as follows. As the columns, UT-807 (single column)manufactured by Showa Denko K.K., and GMHHR-H (S) HT (two columns)manufactured by Tohso Corporation were used and connected in series. TCBwas used as the mobile phase and the sample concentration was 20 to 30mg ((C) polyethylene resin)/20 mL (TCB). Measurement was performed at acolumn temperature of 140° C., a flow rate of 1.0 ml/minute and using adifferential refractometer as a detector.

The weight-average molecular weight was calculated using PMMA as astandard substance.

Note that, since the polyethylene resin (C4) has a high molecular weightand contains a component undissolved in trichlorobenzene, measurement ofthe molecular weight was not made by GPC. Thus, the molecular weight wasmeasured by the viscosity method according to JIS K7367-3.

Examples 1 to 13, Comparative Examples 1 to 6

Resin compositions were prepared such that individual components werecontained in the ratios shown in Table 1 or Table 2, and extruded in theconditions shown in Table 1 or Table 2. The resultant resin compositionswere subjected to molding under the above conditions to produce moldedarticles. The evaluation results for the physical properties are shownin Table 1, Table 2 and Table 5.

TABLE 1 Example Example Example Example Example Example Example Example1 2 3 4 5 6 7 8 Polyacetal resin A1 50 50 A2 A3 100 100 100 100 100 10050 50 Glass filler B1 25 35 35 55 55 35 35 B2 35 B3 Process — 1 1 2 1 21 1 2 Torque % 59 70 72 68 71 70 72 74 Deposition g/hr <1 <1 <1 <1 2 <1<1 2 Amount of chips ppm 2000 2400 2800 2500 3000 2900 2500 3100 Tensilefracture stress MPa 135 151 149 179 176 146 150 148 Bending elasticmodulus MPa 7000 8200 8300 10500 11000 8100 8300 8400 Ratio of glassfiller — 20.0 25.9 25.9 35.5 35.5 25.9 25.9 25.9 (Tensile fracturestress - — 3.50 3.32 3.24 3.21 3.13 3.12 3.28 3.20 65)/Glass fillerratio Average thickness of μm 1.3 1.3 1.2 1.0 0.8 1.1 1.0 0.8 componentcovering the surface of glass filler Creep rupture time hr 600 >20001700 >2000 >2000 1700 1000 700 Wear resistance (depth) μm 18 21 22 26 2923 26 27 against SUS304 ball Dynamic friction — 0.36 0.38 0.38 0.40 0.440.42 0.40 0.41 coefficient against SUS304 ball Molding cycleCycles >50 >50 >50 >50 >50 >50 >50 >50

TABLE 2 Comparative Example Example Example Example Example Example 9 1011 12 13 1 Polyacetal resin A1 100 100 100 100 A2 100 A3 100 Glassfiller B1 35 55 35 80 B2 35 B3 35 Process — 1 1 1 1 1 1 Torque % 72 7172 56 71 71 Deposition g/hr 4 6 4 5 4 23 Amount of chips ppm 4100 48004000 4200 3300 8600 Tensile fracture stress MPa 142 169 141 145 195 128Bending elastic modulus MPa 8300 10200 8300 8400 12800 8500 Ratio ofglass filler — 25.9 35.5 25.9 25.9 44.4 25.9 (Tensile fracture stress -— 2.97 2.93 2.93 3.09 2.93 2.43 65)/Glass filler ratio Average thicknessof μm 0.3 0.3 0.3 0.4 0.9 0.0 component covering the surface of glassfiller Creep rupture time hr 550 760 500 620 >2000 70 Wear resistance(depth) μm 26 33 31 25 32 42 against SUS304 ball Dynamic friction — 0.430.45 0.45 0.43 0.46 0.52 coefficient against SUS304 ball Molding cycleCycles >50 >50 48 >50 >50 34 Comparative Comparative ComparativeComparative Comparative Example Example Example Example Example 2 3 4 56 Polyacetal resin A1 100 100 A2 100 A3 100 100 Glass filler B1 35 5 B2B3 55 35 35 Process — 1 1 2 2 1 Torque % 69 55 74 71 65 Deposition g/hr29 28 12 15 <1 Amount of chips ppm 10000 10600 6000 6500 1900 Tensilefracture stress MPa 141 128 139 138 82 Bending elastic modulus MPa 115008600 8400 8500 3700 Ratio of glass filler — 35.5 25.9 25.9 25.9 4.8(Tensile fracture stress - — 2.14 2.43 2.85 2.82 3.57 65)/Glass fillerratio Average thickness of μm 0.0 0.0 0.1 0.1 1.2 component covering thesurface of glass filler Creep rupture time hr 120 90 280 200 50 Wearresistance (depth) μm 52 41 28 34 27 against SUS304 ball Dynamicfriction — 0.59 0.51 0.48 0.46 0.36 coefficient against SUS304 ballMolding cycle Cycles 32 38 40 34 >50

In Examples 1 to 13, the average thickness of a resin covering thesurface of the glass filler (B) fell within the range of 0.2 μm to 3.0μm. Owing to this, creep resistance, wear resistance, sliding propertyand molding productivity were improved.

Of them, like Examples 1 to 8 and Example 13, in the case where apolyacetal resin (A3) having a block component was used as thepolyacetal resin (A) and glass filler (B1 or B2) modified by afilm-forming agent containing acid was used as the glass filler (B), theaverage thickness of a component covering the surface of the glassfiller (B) became as large as 0.8 μm or more. Owing to this, not onlycreep resistance and sliding property were further improved but alsoamounts of deposition and chips during a production process weresuccessfully decreased.

In contrast, Comparative Examples 1 to 5, the average thickness of acomponent covering the surface of the glass filler (B) was less than 0.2μm.

Of them, like Comparative Examples 1 to 3, in the case where apolyacetal resin (A3) having a block component was not used as thepolyacetal resin (A) and a glass filler (B1 or B2) modified with afilm-forming agent containing acid was not used as the glass filler (B),resin coating over the surface of the glass filler (B) was not observed.In this case, not only creep resistance, wear resistance, slidingproperty and molding productivity decreased but also the amounts ofdeposition and chips during a production process increased.

When Example 9 is compared to Comparative Example 4, it was found that,the average thickness of a resin covering the surface of the glassfiller (B) tends to increase by use of Process 1 in which the kneadingtime after the glass filler (B) is introduced is long.

When Example 1 is compared to Comparative Example 6, it was found thatin Comparative Example 6 where the amount of glass filler (B) is low,even if the average thickness of the resin covering the surface of theglass filler (B) is as sufficient as 1.2 μm, the effect of improvingcreep resistance cannot be obtained

Examples 14 to 26, Comparative Examples 7 to 9

Resin compositions were prepared such that individual components werecontained in the ratios shown in Table 3 or 4, and extruded in theconditions shown in Table 3 or 4. The resulting resin compositions weresubjected to molding under the above conditions to produce moldedarticles. The evaluation results for the physical properties are shownin Table 3 to Table 5.

TABLE 3 Example Example Example Example Example Example Example Example14 15 16 17 18 19 20 21 Polyacetal resin A1 100 100 A2 A3 100 100 100100 100 100 Glass filler B1 35 35 35 35 35 35 55 55 B2 B3 Polyethyleneresin C1 2 1 2 2 5 2 2 C2 C3 C4 2 Process — 1 1 1 1 2 1 1 2 Torque % 6371 64 61 62 54 59 60 Deposition g/hr <1 19 <1 <1 <1 <1 <1 <1 Amount ofchips ppm 2900 5200 1900 1500 1700 1500 2100 2600 Tensile fracturestress MPa 141 140 149 147 148 140 173 175 Bending elastic modulus MPa8100 8100 8100 8100 8200 8000 10200 10400 Ratio of glass filler — 25.525.5 25.7 25.5 25.5 25.0 35.0 35.0 (Tensile fracture stress - — 2.972.94 3.26 3.21 3.25 3.00 3.08 3.14 65)/Glass filler ratio Averagethickness of μm 0.3 0.3 1.1 1.2 1.0 1.1 1.0 0.7 component covering thesurface of glass filler Surface polyethylene ratio — 1.09 0.98 1.11 1.121.12 1.13 1.10 1.09 Creep rupture time hr 420 290 >2000 >2000 17001200 >2000 >2000 Wear resistance (depth) μm 8 14 6 4 5 2 5 6 againstSUS304 ball Dynamic friction coefficient — 0.20 0.32 0.21 0.16 0.16 0.140.16 0.18 against SUS304 ball Molding cycle Cycles >5048 >50 >50 >50 >50 >50 >50

TABLE 4 Example Example Example Example Example Comparative ComparativeComparative 22 23 24 25 26 Example 7 Example 8 Example 9 Polyacetalresin A1 50 100 100 A2 100 A3 100 100 100 100 50 Glass filler B1 35 3535 35 B2 35 B3 35 35 35 Polyethylene resin C1 2 2 2 C2 2 C3 2 C4 2 2 2Process — 1 1 1 1 1 1 1 1 Torque % 64 68 69 63 62 63 70 57 Depositiong/hr <1 3 8 <1 <1 3 32 39 Amount of chips ppm 2100 2200 3900 2200 19006700 10300 11100 Tensile fracture stress MPa 145 145 143 142 149 115 117120 Bending elastic modulus MPa 8200 8100 8100 8000 8300 8400 8300 8400Ratio of glass filler — 25.5 25.5 25.5 25.5 25.5 25.5 25.5 25.5 (Tensilefracture stress - — 3.13 3.13 3.05 3.01 3.29 1.96 2.04 2.15 65)/Glassfiller ratio Average thickness of μm 1.1 1.1 1.0 0.9 0.9 0.0 0.0 0.0component covering the surface of glass filler Surface polyethyleneratio — 1.06 1.03 1.00 1.12 1.11 1.10 0.98 0.96 Creep rupture timehr >2000 1800 1350 1600 900 50 60 40 Wear resistance (depth) μm 7 6 12 65 10 19 18 against SUS304 ball Dynamic friction — 0.22 0.20 0.29 0.170.17 0.20 0.26 0.26 coefficient against SUS304 ball Molding cycleCycles >50 >50 >50 >50 >50 42 38 40

In Examples 14 to 26, the average thickness of a resin covering thesurface of the glass filler (B) fell within the range of 0.2 μm to 3.0μm and satisfactory creep resistance, wear resistance, sliding propertyand molding productivity were obtained. Furthermore, in these Examplescontaining a polyethylene (C), wear resistance and sliding property weremore improved.

From comparison between Examples 14 and 15 and comparison betweenExamples 17, 22, 23 and 24, when a polyethylene (C1, C2 or C3) having aweight-average molecular weight of 500,000 or less was used, it wasfound that polyethylene is easily localized in the surface of a moldedarticle, sliding property and wear resistance can be more improved.

In contrast, in Comparative Examples 7 to 9, since a polyacetal resinhaving a block component (A3) was not used as the polyacetal resin (A)and a glass filler (B1 or B2) modified with a film-forming agentcontaining acid was not used as the glass filler (B), resin coating overthe surface of the glass filler (B) was not observed. In this case,creep resistance decreased, and the amounts of deposition and chipsincreased at the time of manufacture.

TABLE 5 Example Example Example Example Comparative Comparative 2 4 1720 Example 1 Example 8 Polyacetal resin A1 100 100 A2 A3 100 100 100 100Glass filler B1 35 55 35 55 B2 B3 35 35 Polyethylene resin C1 2 2 C2 C3C4 2 Process — 1 1 1 1 1 1 Dynamic friction coefficient (initial — 0.330.35 0.12 0.14 0.40 0.36 sliding property) against a SUS304 ball)Dynamic friction coefficient against — 0.34 0.35 0.24 0.26 0.42 0.32SS400 flat plate Dynamic friction coefficient between the — 0.52 0.550.28 0.29 0.78 0.42 same materials Cantilever bending vibration fatiguekgf/m2 42 50 42 50 28 25 SFD cm 28 26 30 31 23 22

The present application was based on Japanese Patent Application No.2014-070201 filed Mar. 28, 2014, the contents of which are incorporatedherein by reference.

INDUSTRIAL APPLICABILITY

The polyacetal resin composition and molded article of the presentinvention have industrial applicability in a variety of fields in whicha polyacetal resin is suitably used, particularly, in the field of theautomobile mechanical parts requiring durability and sliding property.

The invention claimed is:
 1. A molded article formed from a polyacetalresin composition containing 100 parts by mass of a polyacetal resin(A), 10 parts by mass or more and 100 parts by mass or less of a glassfiler (B), and a polyethylene resin (C) having a weight-averagemolecular weight of 500,000 or less, wherein, an amount of thepolyethylene resin (C) having a weight-average molecular weight of500,000 or less in a surface layer of the molded article is larger thanan amount of the polyethylene resin (C) having a weight-averagemolecular weight of 500,000 or less in a layer surface deeper than 1,000μm from the surface layer of the molded article as measured by cuttingout the layer, and when the molded article is fractured by applicationof tensile force, the surface of the glass filler (B) protruding from afractured surface of a fractured molded article is covered with acomponent comprising the polyacetal resin (A) having an averagethickness of 0.2 μm or more and 3.0 μm or less.
 2. A molded articleformed from a polyacetal resin composition containing 100 parts by massof a polyacetal resin (A), 10 parts by mass or more and 100 parts bymass or less of a glass filler (B), and a polyethylene resin (C) havinga weight-average molecular weight of 500,000 or less, wherein, an amountof the polyethylene resign (c) having a weight-average molecular weightof 500,000 or less in a surface layer of the molded article is largerthan an amount of the polyethylene resin (C) having a weight-averagemolecular weight of 500,00 or less in a layer surface deeper than 1,000μm from the surface layer of the molded article as measured by cuttingout the layer; a tensile fracture stress of the molded article measuredin accordance with ISO527-1 is 135 MPa or more; a bending elasticmodulus of the molded article measured in accordance with ISO178 is 7500MPa or more; and a value of (tensile fracture stress—65)(MPa)/glassfiller ratio (mass %) is 2.90 or more.
 3. The molded article accordingto claim 2, wherein when the molded article is fractured by applicationof tensile force, the surface of the glass filler (B) protruding from afractured surface of a fractured molded article is covered with acomponent comprising the polyacetal resin (A) having an averagethickness of 0.2 μm or more and 3.0 μm or less.
 4. The molded articleaccording to claim 1, wherein the polyethylene resin (C) having aweight-average molecular weight of 500,000 or less is present in anamount of 0.5 parts by mass or more and 8 parts by mass or less based on100 parts by mass of the polyacetal resin (A).
 5. The molded articleaccording to claim 4, wherein the polyethylene resin (C) having aweight-average molecular weight of 500,000 or less has a melting pointof 115° C. or less.
 6. The molded article according to claim 1, whereinat least one acid is contained as a material having a function ofmodifying the surface of the glass filler (B).
 7. The molded articleaccording to claim 6, wherein the acid is carboxylic acid.
 8. The moldedarticle according to claim 1, wherein the polyacetal resin (A) containsa block component.
 9. The molded article according to claim 8, whereinthe block component is a hydrogenated polybutadiene component.
 10. Amethod for preparing the molded article according to claim 6, comprisinga step of modifying a surface of the glass filter (B) with the materialcontaining the at least one acid, and a step of mixing the modifiedglass filler and the polyacetal resin (A).
 11. The molded articleaccording to claim 2, wherein the polyethylene resin (C) having aweight-average molecular weight of 500,000 or less is present in anamount of 0.5 parts by mass or more and 8 parts by mass or less based on100 parts by mass of the polyacetal resin (A).
 12. The molded articleaccording to claim 11, wherein the polyethylene resin (C) having aweight-average molecular weight of 500,000 or less has a melting pointof 115° C. or less.
 13. The molded article according to claim 2, whereinat least one acid is contained as a material having a function ofmodifying the surface of the glass filler (B).
 14. The molded articleaccording to claim 13, wherein the acid is carboxylic acid.
 15. Themolded article according to claim 2, wherein the polyacetal resin (A)contains a block component.
 16. The molded article according to claim15, wherein the block component is a hydrogenated polybutadienecomponent.
 17. A method for preparing the molded article according toclaim 13, comprising a step of modifying a surface of the glass filler(B) with the material containing the at least one acid, and a step ofmixing the modified glass filler and the polyacetal resin (A).
 18. Themolded article according to claim 4, wherein at least one acid iscontained as a material having a function of modifying the surface ofthe glass filler (B).
 19. The molded article according to claim 18,wherein the polyacetal resin (A) contains a block component.
 20. Themolded article according to claim 6, wherein the polyacetal resin (A)contains a block component.